MAINTENANCE

1. Presentation on Maintenance
By
SUNEEL KUMAR
UGT ENTERPRISE

2. Maintenance
 Maintenance and reliability is important
 Maintenance and product quality
 Maintenance and productivity
 Maintenance and safety
 Maintenance and supply chain, JIT
 Failure cause disruption, waste,
accident, inconvenience and expensive

3.  Operators less able to do repairs
themselves
 Machine and product failure can have
effect on company’s operation and
profitability
 Idle workers, facility
 Losses due to breakdown

4. Failure
 Failure – inability to produce work in
appropriate manner
 Equipment / machine failure on production
floor – worn out bearing, pump, pressure
leaks, broken shaft, overheated machine etc.
 Equipment failure in office – failure of power
supply, air-conditioned system, computer
network, photocopy machine
 Vehicle failure – brake, transmission, engine,
cooling system

5. Question?
 Why do we need maintenance?
 What are the costs of doing
maintenance?
 What are the costs of not doing
maintenance?
 What are the benefits of maintenance?
 How can maintenance increase
profitability of company?

6. Purpose of Maintenance
 Attempt to maximize performance of
production equipment efficiently and
regularly
 Prevent breakdown or failures
 Minimize production loss from failures
 Increase reliability of the operating
systems

7. Principle Objectives in
Maintenance
 To achieve product quality and customer
satisfaction through adjusted and serviced
equipment
 Maximize useful life of equipment
 Keep equipment safe and prevent safety
hazards
 Minimize frequency and severity of
interruptions
 Maximize production capacity – through high
utilization of facility

8. Problems in Maintenance
 Lack of management attention to
maintenance
 Little participation by accounting in analyzing
and reporting costs
 Difficulties in applying quantitative analysis
 Difficulties in obtaining time and cost
estimates for maintenance works
 Difficulties in measuring performance

9. Maintenance Objectives
 Must be consistent with the goals of
production (cost, quality, delivery,
safety)
 Must be comprehensive and include
specific responsibilities

10. Maintenance Costs
 Cost to replace or repair
 Losses of output
 Delayed shipment
 Scrap and rework

11. Types of Maintenance
 Maintenance may be classified into four categories:
 (some authors prefer three categories- scheduled
and preventive maintenances are merged)
 Corrective or Breakdown maintenance
 Scheduled maintenance
 Preventive maintenance
 Predictive (Condition-based) maintenance

12. Corrective or Breakdown
Maintenance
 Corrective or Breakdown maintenance
implies that repairs are made after the
equipment is failed and can not perform its
normal function anymore
 Quite justified in small factories where:
– Down times are non-critical and repair costs are
less than other type of maintenance
– Financial justification for scheduling are not felt

13. Preventive Maintenance (PM)
 Principle – “Prevention is better than cure”
 Procedure - Stitch-in-time
 It
– locates weak spots of machinery and equipments
– provides them periodic/scheduled inspections and
minor repairs to reduce the danger of
unanticipated breakdowns

14. Advantages of PM
 Advantages:
–Reduces break down and thereby down time
–Lass odd-time repair and reduces over time of
crews
–Greater safety of workers
–Lower maintenance and repair costs
–Less stand-by equipments and spare parts
–Better product quality and fewer reworks and
scraps
–Increases plant life
–Increases chances to get production incentive
bonus

15. Maintenance Costs
MaintenanceMaintenance
CommitmentCommitment
CostCost
Breakdown CostBreakdown Cost

16. Thanks you